Frame kit for PC card, PC card, and method of manufacturing PC Card

ABSTRACT

A PC card frame kit is provided which comprises: a frame for retaining a board assembly having a connector mounted on a board; and a pair of panels for covering upper and lower faces of the board assembly mounted in the frame. The pair of panels each have a pivotal engagement piece provided on a rear edge thereof for pivotal engagement with the frame, front lock engagement pieces provided on front ends of opposite side edges thereof for lock engagement between the panels, and a press-fit piece provided on at least one of the side edges thereof to be press-fitted in the frame. The frame has a pivotal engagement piece receiving groove formed in a rear beam thereof for receiving the pivotal engagement piece in a rotatable manner, and a press-fit groove formed in at least one of opposite side beams associated with the press-fit piece for receiving the press-fit piece.

TECHNICAL FIELD

The present invention relates to a PC card frame kit, a PC card and a PCcard production method. The term “PC card” is herein to be understood toinclude PC cards in a narrow sense, cards for communications such asmemory cards and LAN cards, smart cards, small PC cards, CF (compactflash (trade mark)) cards, and other cards having constructions similarto the PC cards in a narrow sense.

BACKGROUND ART

Notebook personal computers, for example, are typically provided with aPC card slot, in which a PC card is fitted for extension of theircapabilities. The PC card is of a card shape as a whole, and includes aboard assembly having a connector mounted on a board for connection tothe PC card slot, a frame retaining the board assembly, and a pair ofmetal panels covering upper and lower surfaces of the board assembly.

PC card production processes are generally classified into a mechanicalproduction process which is suitable formass production and a manualproduction process which is suitable for relatively small volumeproduction of various types of products. In the mechanical productionprocess, metal panels are fixed to a frame such as molded from a resinwith the use of a ultrasonic fusion bonding apparatus or the like. Inthe manual production process, on the contrary, a pair of metal panelsare manually combined with each other by pressing the pair of metalpanels toward each other by fingers or a jig with a board assembly and aframe held therebetween for assembling a PC card.

In a PC card frame kit (including the frame and the pair of metalpanels) for use in the manual assembling process, for example,engagement members to be brought into lock engagement with each otherare provided on side edges of the pair of metal panels. In theassembling, these engagement members are engaged with each other throughthrough-holes formed in the frame, whereby the pair of metal panels arecombined with each other and with the frame simultaneously.

However, this arrangement inevitably entails a loose connection betweenthe metal panels and the frame. The loose connection practicallypresents no functional problem, but the PC card is mechanicallyunstable, thereby falling short of product perfection. In addition, thePC card may become disassembled if a great shock is applied thereto, forexample, when the card is dropped on the floor.

One approach to solve this problem in the prior art is disclosed, forexample, in Japanese Unexamined Patent Publication No. 9-153121 (1997).The prior art approach is intended to improve the mechanical stabilityof a PC card by resiliently biasing a pair of panels outward byresilient press members provided in a frame.

However, the prior art approach fails to assuredly prevent thedisassembly of the PC card which may occur if a great shock is appliedto the card, for example, when the card is dropped on the floor, becausethe looseness occurs within the range of resilient deformation of theresilient press members.

The panels, when pressed toward each other, are slightly deformed due todeformation of the resilient press members. Therefore, the PC card isnot satisfactory in terms of product perfection.

The PC card is assembled by first positioning the pair of panels withrespect to the frame and then combining the pair of panels with eachother. However, the positioning of the panels with respect to the frameis not necessarily easy, resulting in difficulty in the assembling. Thisleads to a lower PC card assembling efficiency.

DISCLOSURE OF THE INVENTION

It is an object of the present invention to provide a PC card frame kitwhich provides a PC card free from any looseness, and to provide a PCcard utilizing such a PC card frame kit.

It is another object of the invention to provide a PC card frame kitwhich provides a PC card having an improved resistance to an externalforce, and to provide a PC card utilizing such a PC card frame kit.

It is further another object of the invention to provide a productionmethod for a PC card which ensures easy assembling of the PC card.

A PC card frame kit according to the present invention comprises: aframe for retaining a board assembly having a connector mounted on aboard; and a pair of panels for covering upper and lower faces of theboard assembly mounted in the frame, wherein the pair of panels eachhave a pivotal engagement piece provided on a rear edge thereof forpivotal engagement with the frame, front lock engagement pieces providedon front ends of opposite side edges thereof for lock engagement betweenthe panels, and a press-fit piece provided on at least one of the sideedges thereof to be press-fitted in the frame, wherein the frame has apivotal engagement piece receiving groove formed in a rear beam thereoffor receiving the pivotal engagement piece in a rotatable manner, and apress-fit groove formed in at least one of opposite side beamsassociated with the press-fit piece for receiving the press-fit piece.

With this inventive arrangement, the press-fit pieces of the panels arepress-fitted in the press-fit groove of the frame, so that the looseconnection between the pair of panels can be eliminated. Therefore, evenif a great shock is applied to the PC card, for example, when the PCcard is dropped on the floor, the PC card is prevented from becomingdisassembled. Further, even if a torsion is applied to the PC card, theframe and the panels are accordingly deformed by the effect of thepress-fit pieces and the press-fit groove, so that there is nopossibility that the panels are disengaged from each other or from theframe. Thus, a PC card having a higher level of product perfection canbe provided.

Since the panels are each combined with the frame by engaging thepivotal engagement piece with the pivotal engagement piece receivinggroove and then rotating the panel with respect to the frame, the panelscan easily be positioned with respect to the frame along the side edgesof the panels. Further, the front lock engagement pieces are broughtinto lock engagement with each other, so that the panels are preventedfrom being disengaged from each other.

It is preferred that press-fit pieces are provided on both of theopposite side edges of each of the panels. Thus, the looseness can moreassuredly be prevented.

The pivotal engagement piece preferably has an open square cross sectionperpendicular to the rear edge. Thus, the pivotal engagement piece canassuredly be connected to the frame, so that the disassembly of the PCcard can be prevented.

A plurality of pivotal engagement piece receiving grooves may beprovided in the rear beam of the frame in such an arrangement that aspace can be reserved in which the connector or the like is mounted.

The pivotal engagement piece receiving groove preferably has apositioning abutment portion which is to abut against the pivotalengagement piece for positioning the panels with respect to the framealong the rear edges of the pair of panels.

With this arrangement, the positioning of the panels with respect to theframe along the rear edges of the panels can easily be achieved. Thus,the assembling of the PC card is further facilitated.

The positioning abutment portion may be provided at an end of thepivotal engagement piece receiving groove to abut against a side face ofthe pivotal engagement piece.

The pair of panels preferably each further have a side lock pieceprovided on at least one of the opposite side edges thereof for lockengagement between the panels.

With this inventive arrangement, the side edges of the panels areconnected by the lock engagement, so that the pair of panels canassuredly be combined with each other.

It is preferred that side lock pieces are provided on both of theopposite side edges of each of the panels. Thus, the panels areassuredly prevented from being disengaged from each other.

It is preferred that the side lock pieces respectively provided on thepair of panels are resilient pieces, one of which is formed with a hookportion for preventing disengagement, and the other of which is formedwith an engagement hole for receiving the hook portion for snapengagement with the hook portion.

With this arrangement, the side lock pieces are resiliently engaged witheach other, so that the snap engagement therebetween can easily beachieved and the hook portion in the snap engagement is assuredlyprevented from being disengaged from the engagement hole. Thus, thepanels can more assuredly be combined with each other.

Alternatively, the side lock piece provided on one of the pair of panelsis preferably a resilient member having an upstanding portion extendingupward from the side edge of the panel to fit along the side beam of theframe, and a hook portion extending from the upstanding portion inwardlyof the frame. In this case, the side lock piece provided on the otherpanel is preferably a resilient member having a downstanding portionextending downward from the side edge of the panel to fit along the sidebeam of the frame, a guide portion extending obliquely from thedownstanding portion inwardly of the frame for guiding the hook portion,and an engagement hole formed in a proximal portion of the guideportion. It is preferred that the hook portion is guided into theengagement hole by the guide portion to be brought into snap engagementwith the engagement hole by pressing the pair of panels toward eachother in an opposed relation.

With this arrangement, the side lock pieces respectively provided on theside edges of the pair of panels are configured as the resilientmembers. Therefore, the both of resilient members are deformed when thepair of panels are pressed toward each other and the hook portionprovided on the one panel is guided by the guide portion provided on theother panel. More specifically, the upstanding portion of the side lockpiece on the one panel is resiliently deformed outwardly of the frame,while the downstanding portion (and the guide portion) of the side lockpiece of the other panel is resiliently deformed inwardly of the frame.When the hook portion reaches the engagement hole, the side lock piecesare restored into their original shapes, whereby the snap engagementbetween the hook portion and the engagement hole is achieved. Since thepair of side lock pieces are each resiliently deformed, the snapengagement can easily be achieved.

Once the pair of side lock pieces are engaged with each other,disengagement of the side lock pieces is not easy. Since the engagementof the resilient members is achieved by causing the resilient members tobe resiliently deformed away from each other and then to be restoredinto their original shapes, the hook portion and the engagement hole arekept in firm lock engagement. For release from the lock engagement, itis necessary to resiliently deform the side lock pieces to bring thehook portion and the guide portion away from each other by applying aforce to the side lock piece of the one panel outwardly from the insideof the frame while applying a force to the side lock piece of the otherpanel inwardly from the outside of the frame. With the pair of side lockpieces being engaged with each other, however, it is impossible to applyan external force to the hook portion outwardly of the frame from theoutside of the frame. Further, the guide portion is located inwardly ofthe junction between the pair of side lock pieces, so that it isimpossible to apply an external force to the guide portion. With thisinventive arrangement, therefore, the pair of panels can be combinedwith each other in a non-disassemblable manner, so that there is nopossibility that the PC card thus assembled by combining the pair ofpanels becomes disassembled.

Alternatively, one of the pair of panels preferably has upstandingportions extending upward from generally entire portions of the oppositeside edges thereof, and first abutment portions extending from generallyentire distal edges of the upstanding portions bent inwardly of theframe. In this case, the other panel preferably has downstandingportions extending downward from generally entire portions of theopposite side edges of the panel, and second abutment portions extendingfrom generally entire distal edges of the downstanding portions bentinwardly of the frame to be opposed to the first abutment portions. Itis preferred that the first abutment portions respectively abut againstthe second abutment portions with the pair of panels combined with eachother.

With this arrangement, the pair of panels respectively have the firstabutment portions and the second abutment portions which bend and extendinwardly of the frame from the generally entire portions of the oppositeside edges thereof. With the pair of panels combined with each other,therefore, generally entire edge faces of the opposite side edges of thepair of panels are directed inwardly of the frame, and the firstabutment portions and the second abutment portions abut against, so thatthese end faces are not exposed to the outside. Thus, a PC card having agood appearance can be provided.

Where the aforesaid two features associated with the construction of theside edges of the panels are employed in combination, the panels may beconfigured such that: the upstanding portions extend from the generallyentire portions of the opposite side edges of the one panel; thedownstanding portions extend from the generally entire portions of theopposite side edges of the other panel; the hook portions extend fromthe distal edges of the first abutment portions; and the guide portionsextend from the distal edges of the second abutment portions.

In this case, the hook portions are preferably each held between an edgeface of the engagement hole and the second abutment portion with thepair of side lock pieces engaged with each other. Thus, the secondabutment portion resiliently abuts against the hook portion, whereby thelooseness can be eliminated. The hook portion which is assuredly lockedby the edge face of the engagement hole is assuredly prevented frombeing disengaged from the engagement hole.

Another PC card frame kit according to the present invention comprises:a frame for retaining a board assembly having a connector mounted on aboard; and a pair of panels for covering upper and lower faces of theboard assembly mounted in the frame, wherein the pair of panels eachhave a side lock piece provided on at least one of opposite side edgesthereof for lock engagement between the panels, wherein the side lockpiece provided on one of the pair of panels is a resilient member havingan upstanding portion extending upward from the side edge of the panelto fit along a side beam of the frame, and a hook portion extending fromthe upstanding portion inwardly of the frame, wherein the side lockpiece provided on the other panel is a resilient member having adownstanding portion extending downward from the side edge of the panelto fit along the side beam of the frame, a guide portion extendingobliquely from the downstanding portion inwardly of the frame forguiding the hook portion, and an engagement hole formed in a proximalportion of the guide portion, wherein the hook portion is guided intothe engagement hole by the guide portion to be brought into snapengagement with the engagement hole by pressing the pair of panelstoward each other in an opposed relation.

In accordance with the invention, a robust PC card can be provided whichis easy to assemble and will never become disassembled after theassembling.

In this case, it is preferred that: the upstanding portion extendsgenerally entirely along each of the opposite side edges of the onepanel; the downstanding portion extends generally entirely along each ofthe opposite side edges of the other panel; the one panel furtherincludes a first abutment portion extending from a generally entiredistal edge of the upstanding portion inwardly of the frame to connectthe upstanding portion to the hook portion; the other panel furtherincludes a second abutment portion extending from a generally entiredistal edge of the downstanding portion inwardly of the frame to connectthe downstanding portion to the guide portion.

With this arrangement, a PC card having a good appearance can beprovided.

In this case, the hook portion is preferably held between an edge faceof the engagement hole and the second abutment portion with the pair ofside lock pieces engaged with each other. Thus, the second abutmentportion resiliently abuts against the hook portion, whereby the looseconnection can be eliminated. The hook which is assuredly locked by theedge face of the engagement hole is assuredly prevented from beingdisengaged from the engagement hole.

The frame may be a unitary rectangular ring member having a generallyrectangular shape. The term “rectangular ring member having a generallyrectangular shape” herein means a closed ring frame having a generallyrectangular shape including a square shape.

With this arrangement, the unitary frame is less liable to be deformedas compared with a case where the frame is composed of a plurality ofseparate members. Therefore, the assembled PC card is assuredlyprevented from being loosened, and imparted with a higher resistance toan external force. In addition, when the panels are to be combined withthe frame, the panels can easily be positioned with respect to theframe, so that the assembling of the PC card is advantageouslyfacilitated.

A PC card according to the present invention comprises the aforesaidframe kit and a board assembly, wherein the pair of panels are combinedwith the frame with the board assembly retained between the pair ofpanels.

With this inventive arrangement, the panels are assuredly joinedtogether in press-fit engagement against the frame, so that the panelscan be combined with each other without any looseness and assuredlycombined with the frame. Therefore, even if a great external force isapplied to the PC card, for example, when the PC card is dropped on thefloor or subjected to torsion, there is no possibility that the PC cardbecomes disassembled.

In accordance with the present invention, there is provided a PC cardproduction method, in which a first panel and a second panel areattached to a frame retaining a board assembly having a connectormounted on a board to cover upper and lower faces of the board assemblymounted in the frame, the PC card production method comprising the stepsof: bringing a pivotal engagement piece provided on a rear edge of thefirst panel into engagement with a pivotal engagement piece receivinggroove formed in a rear beam of the frame; rotating the first panel withrespect to the frame about the pivotal engagement piece as a rotationaxis until a front edge of the first panel abuts against the frame;bringing a pivotal engagement piece provided on a rear edge of thesecond panel into engagement with the pivotal engagement piece receivinggroove formed in the rear beam of the frame; rotating the second panelwith respect to the frame about the pivotal engagement piece as arotation axis until a front edge of the second panel abuts against theframe; and pressing the first and second panels against the frame tocombine the first and second panels with each other and with the frame.

In accordance with the invention, the panels are combined with the frameafter the pivotal engagement pieces are engaged with the pivotalengagement piece receiving groove of the frame and the panels arerotated about the pivotal engagement pieces as the rotation axes.Therefore, the panels can easily be positioned with respect to the framealong the side edges of the first and second panels.

Since the first and second panels are combined with each other and withthe frame, the PC card thus produced has an improved resistance to anexternal force.

In this case, the combining step preferably comprises the steps of:engaging front lock engagement pieces provided on front end portions ofopposite side edges of the first panel with front lock engagement piecesprovided on front end portions of opposite side edges of the secondpanel; and press-fitting a press-fit piece provided on at least one ofthe side edges of each of the first and second panels into a press-fitgroove formed in the frame.

Thus, the front lock engagement pieces are brought into lock engagementwith each other, so that the PC card thus produced has the panelsassuredly combined with each other.

Since the press-fit pieces of the respective panels are press-fitted inthe press-fit groove of the frame, the PC card thus produced is freefrom any looseness, and has a higher resistance to an external force.

The press-fit pieces of the first and second panels may be press-fittedin the press-fit groove of the frame either simultaneously orsuccessively.

The foregoing and other objects, features and effects of the presentinvention will become more apparent from the following description ofthe embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a PC card according to oneembodiment of the present invention;

FIG. 2 is a perspective view illustrating a frame as seen from the backside thereof;

FIG. 3 is a perspective view illustrating the construction of a lowerpanel;

FIG. 4 is a perspective view illustrating an upper panel as seen fromthe back side thereof;

FIGS. 5A, 5B and 5C are major sectional views illustrating a processsequence for engaging an upper side lock piece with a lower side lockpiece;

FIG. 6 is a major perspective view for explaining engagement of an upperfront lock engagement piece with a lower front lock engagement piece;

FIGS. 7A to 7F are schematic side views illustrating a process sequencefor combining the upper and lower panels with the frame; and

FIG. 8 is a major perspective view of a PC card according to anotherembodiment of the present invention.

EMBODIMENTS OF THE INVENTION

FIG. 1 is an exploded perspective view illustrating the construction ofa PC card 1 according to one embodiment of the present invention.Referring to FIG. 1, the PC card 1 includes a printed board 2,connectors 3, 4 mounted on the printed board 2, a frame 6 retaining aboard assembly 5 having the first and second connectors 3, 4 mounted onfront and rear edges of the printed board 2, and a pair of metal panels7, 8 covering upper and lower faces of the board assembly 5 mounted inthe frame 6.

The first connector 3 is used for electrical connection between theprinted board 2 and an external connector (not shown), while the secondconnector 4 is used for electrical connection between a PC card slot(not shown) and the printed board 2. In the following explanation, theside of the second connector 4 to be connected to the PC card slot isregarded as the front side, and the side of the first connector 3 isregarded as the rear side.

The printed board 2 has a cutaway portion (not shown) provided in a rearedge thereof for receiving the first connector 3. Projections (notshown) provided on the first connector 3 are brought into engagementwith a plurality of engagement holes (not shown) formed in the peripheryof the cutaway portion, whereby the first connector 3 is properlypositioned with respect to the printed board 2 when mounted on theprinted board 2. Thereafter, a first engagement projection (not shown)extending from the first connector 3 is soldered to a predeterminedportion adjacent to the rear edge of the printed board 2, wherebymechanical connection between the first connector 3 and the printedboard 2 is achieved. The connectors 3 and 4 each have a plurality ofcontact leads 10, 10 extending forward and rearward. These contact leadsare soldered onto the printed board 2. The mounting of the secondconnector 4 onto the printed board 2 is achieved by the soldering.

The first connector 3 has a pair of first projections 11 and a pair ofsecond projections 12 which are provided on side faces thereof asextending laterally. Similarly, the second connector 4 has a pair ofthird projections 13 provided on side faces thereof. The printed board 2has positioning holes 2 c provided in four corners thereof forpositioning thereof with respect to the frame 6.

FIG. 2 is a perspective view illustrating the frame as seen from theback side thereof. The frame 6 is a rectangular ring frame unitarilyinjection-molded from a resin. The frame 6 includes a pair of side beams15, 15, a pair of rear beams 16, 16 respectively extending inwardly fromrear ends of the side beams 15, 15, and a front beam 17 connecting eachof the side edges 16, 16 slightly rearward of front ends thereof. Theframe 6 further includes a pair of retention beams 18, 18 extending frominward ends of the pair of rear beams 16, 16 parallel to the side beams15 for retaining side portions 3 a of the first connector 3 (see FIG. 1)when the printed board 2 is accommodated in the frame 6, and aconnection beam 19 connecting front ends of the pair of retention beams18, 18 to define a space in which the first connector 3 is retained.These beams are integrally formed.

A step portion 21 for positioning the printed board 2 on a lower face 6a of the frame 6 is formed in inner surfaces of the side beams 15 andthe rear beams 16. Positioning engagement pieces 23 to be inserted intothe positioning holes 2 c of the printed board 2 are provided upright ona lower step surface 22 of the step portion 21 in four corners of theframe. Lower faces of the front beam 17 and the retention beam 18 areflush with the lower step face 22 so as to abut against a peripheraledge of the upper face of the printed board 2.

The rear beams 16 respectively have first engagement recesses 24 formedin inward end faces thereof as opening downward (upward in FIG. 2) forretaining the first connector 3 in engagement with the first projections11 of the first connector 3 (see FIG. 1). The retention beams 18respectively have second engagement recesses 25 formed in inward facesthereof adjacent the first engagement recesses 24 for retaining thefirst connector 3 in engagement with the second projections 12 of thefirst connector 3 (see FIG. 1).

The side beams 15, 15 respectively have third engagement recesses 26, 26formed in distal end portions thereof for retaining the secondconnectors 4 in engagement with the third projections 13 of the secondconnector 4 (see FIG. 1).

The side beams 15 further each have a through-channel 28 formed alongthe length thereof in a distal end portion thereof as extendingtherethrough from the upper face to the lower face of the frame 6. Thethrough-channel 28 has a width which is twice as great as the thicknessof front lock engagement pieces 50, 68 (see FIGS. 3 and 4) which will bedescribed later. The side beams 15 further each have a fourth projection29 provided forwardly adjacent the middle thereof as projecting outwardfrom the lower face of the frame 6, and the fourth projection 29 isformed with a first press-fit groove 30 extending parallel to the sidebeam 15. The side beams 15 further each have a fifth projection 31provided rearwardly adjacent the middle thereof as projecting outwardfrom the upper face of the frame 6, and the fifth projection 31 isformed with a second press-fit groove 32 extending parallel to the sidebeam 15. The side beams 15 further each have a first engagement groove34 and a second engagement groove 35 (see FIG. 7A) respectively formedalong the length thereof in the lower and upper faces of a rear endportion thereof.

The rear beams 16, 16 respectively have pivotal engagement piecereceiving grooves 33, 33 formed in outer side faces 16 a, 16 a thereofas extending longitudinally thereof. The pivotal engagement piecereceiving grooves 33 each have a pair of abutment portions 33 a, 33 aprovided at opposite ends thereof.

FIG. 3 is a perspective view illustrating a lower panel 8 of the pair ofmetal panels 7, 8 which is located on the lower side in a usual usestate of the PC card 1, and FIG. 4 is a perspective view illustrating anupper panel 7 which is located on the upper side as seen from the backside thereof.

Referring to FIG. 3, the lower panel 8 is a conductive plate of agenerally rectangular shape, and has front cutaway portions 59 and rearcutaway portions 60 located on four corners thereof for exposing thefront and rear end portions of the side beams 15 of the frame 6 afterthe lower panel is combined with the frame 6.

The lower panel 8 has first upstanding portions 61 respectivelyextending upward from opposite side edges 8 a, 8 a thereof generallyentirely along the side edges 8 a, 8 a to fit along the side beams 15 ofthe frame 6, and second upstanding portions 62 respectively extendingupward bent at front end portions of the side edges 8 a thereof. Thelower panel 8 further has a pair of pivotal engagement pieces 63 of agenerally open-square cross section extending upward from a rear edge 8b thereof to fit along the rear beams 16 of the frame 6 and bentinwardly. The pair of pivotal engagement pieces 63, 63 each have apredetermined width along the rear edge 8 b.

Along the side edges 8 a, first abutment portions 67 are respectivelyprovided as extending from entire distal edges 61 a of the firstupstanding portions 61 bent inwardly of the frame 6. Three lower sidelockpieces 64 are provided along each of the side edges 8 a.

Lower front lock engagement pieces 68, 68 are respectively provided onthe front end portions of the side edges 8 a, 8 a. The lower front lockengagement pieces 68 are each formed by forming a generally rectangularengagement hole 69 in a generally central portion of the secondupstanding portion 62 which extends upright to fit along the side beam15 of the frame 6.

A pair of second press-fit pieces 71, 71 to be respectively press-fittedin the second press-fit grooves 32 of the frame 6 are respectivelyprovided rearwardly adjacent the midpoints of the side edges 8 a, 8 a.The second press-fit pieces 71 are configured to extend inwardly to fitalong the side beams 15 of the frame 6 and be bent upwardly.

Second engagement pieces 73 are respectively provided on side edges 60 aof the pair of rear cutaway portions 60 as extending upward to fit alongthe side beams 15 of the frame 6.

Referring to FIG. 4, the upper panel 7 is a conductive plate of agenerally rectangular shape, and has front cutaway portions 39 and rearcutaway portions 40 located on four corners thereof for exposing thefront and rear end portions of the side beams 15 of the frame 6 afterthe upper panel is combined with the frame 6.

The upper panel has pivotal engagement pieces 43 of a generallyopen-square cross section extending downward from a rear edge 7 bthereof to fit along the rear beams 16 of the frame 6 and bent inwardly.The pair of pivotal engagement pieces 43, 43 each have a predeterminedwidth along the rear edge 7 b.

The upper panel 7 has first downstanding portions 41 formed respectivelyto bend and extend downward from opposite side edges 7 a, 7 a thereofgenerally entirely along the side edges 7 a to fit along the side beams15 of the frame 6, and second downstanding portions 42 formedrespectively to bend and extend downward from front end portions of theside edges 7 a thereof. Along the side edges 7 a, second abutmentportions 47 are respectively provided as extending from entire distaledges 41 a of the first downstanding portions 41 bent inwardly of theframe 6. Three upper side lock pieces 44 are provided in a spacedrelation along each of the side edges 7 a. Upper front lock engagementpieces 50 are respectively provided on the front end portions of theside edges 7 a, 7 a. The upper front side lock engagement pieces 50 eachhave a second downstanding portion 42 extending downward to fit alongthe side beam 15 of the frame 6, and an upwardly incised portion 51formed by incising and outwardly raising a generally central portion ofthe second downstanding portion 42. The upper front lock engagementpieces 50 each have a length which is slightly greater than the lengthof the through-channel 28.

First press-fit pieces 53 to be respectively press-fitted in the firstpress-fit grooves 30 of the frame 6 are respectively provided rearwardlyadjacent the midpoints of the side edges 7 a, 7 a. The first press-fitpieces 53 are configured to extend inwardly from the second abutmentportions 47 to fit along the side beams 15 of the frame 6 and be bentdownwardly.

Two generally chevron-shaped conductive pieces 54, 54 extend inwardlydownward from an inner side edge of the second abutment portion 47 onone of the side edges 7 a.

A pair of first engagement pieces 55, 55 are respectively provided onside edges 40 a of the rear cutaway portions 40 as extending downward tofit along the side beams 15 of the frame 6.

FIGS. 5A to 5C are major sectional views for explaining engagement ofthe upper side lock pieces 44 with the lower side lock pieces 64.Referring to FIG. 5A, the lower side lock pieces 64 each include thefirst upstanding portion 61, the first abutment portion 67 bending andextending inwardly from the distal edge 61 a of the first upstandingportion 61, and a hook portion 65 extending from the first abutmentportion 67, and serve as a resilient member as a whole.

On the other hand, the upper side lock pieces 44 each include the firstdownstanding portion 41, the second abutment portion 47 extending fromthe distal edge 41 a of the first downstanding portion 41 bent inwardlyof the frame 6, a guide portion 48 extending obliquely from the distaledge 47 a of the second abutment portion 47 inwardly of the frame 6 forguiding the hook portion 65, and an engagement hole 49 formed in aproximal portion of the guide portion 48, and serve as a resilientmember as a whole.

When the metal panels 7 and 8 are brought into lock engagement with eachother, the guide portion 48 guides the hook portion 65 into engagementwith the engagement hole 49 as shown in FIG. 5B. At this time, the guideportion 48 and a portion of the first upstanding portion 61 of the lowerpanel 8 adjacent to the hook portion 65 are resiliently deformedoutwardly of the frame 6, while the guide portion 48 and a portion ofthe upper panel 7 adjacent to the first downstanding portion 41 areresiliently deformed inwardly of the frame 6. When the inwardlyextending hook portion 65 is thereafter fitted in the engagement hole 49as shown in FIG. 5C, the first upstanding portion 61 of the lower panel8 resiliently outwardly deformed and the first downstanding portion 41and guide portion 48 of the upper panel 7 resiliently inwardly deformedare restored into their original shapes, so that the first abutmentportion 67 and the second abutment portion 47 are brought into abutmentagainst each other.

Thus, the first upstanding portion 61 is first resiliently deformed awayfrom the first downstanding portion 41 and the guide portion 48, andthen the resilient deformation is removed to bring the hook portion 65into engagement with the engagement hole 49. Therefore, firm engagementbetween the hook portion 65 and the engagement hole 49 can be achieved.Once the upper and lower side lock pieces 44, 64 are engaged with eachother, it is extremely difficult to bring the upper and lower side lockpieces 44, 64 out of engagement. This is one factor that imparts the PCcard with a higher resistance to an external force. In addition, thehook portion 65 and the guide portion 48 extend inwardly of the frame 6and, hence, it is difficult to apply a force to the hook portion 65outwardly from the inside of the frame 6 or to apply a force to theguide portion 48 inwardly from the outside of the frame 6. Therefore,the disengagement of the hook portion 65 from the engagement hole 49,which requires both of these force applying operations, is achieved onlywith the use of a special tool or the like. Further, the junctionbetween the hook portion 65 and the engagement hole 49 is locatedinwardly of exposed surfaces of the panels 7, 8 (i.e., the firstupstanding portion 61 and the first downstanding portion 41), making itmore difficult to bring the side lock pieces 44 and 64 out of lockengagement.

With the upper and lower side lock pieces 44, 64 kept in lockengagement, the hook portion 65 is held between the second abutmentportion 47 and a lower edge 49 a of the engagement hole 49. Therefore,the second abutment portion 47 resiliently abuts against the hookportion 65 thereby to prevent loose engagement therebetween. Inaddition, the engagement of the hook portion 65 with the lower edge 49 aof the engagement hole 49 assuredly prevents the disengagement.

FIG. 6 is a major perspective view for explaining engagement of theupper front lock engagement pieces 50 with the lower front lockengagement pieces 68. Referring to FIG. 6, the upper front lockengagement pieces 50 each have a length Wb which is slightly greaterthan the length Wd of the lower front lock engagement piece 68. Further,the length Wb of the upper front lock engagement piece 50 is slightlygreater than the length of the through-channel 28, and the length Wd ofthe lower front lock engagement piece 68 is equal to the length of thethrough-channel 28. The incised portion 51 has a width Wa which issmaller than the width Wc of the engagement hole 69.

When the metal panels 7, 8 are combined with each other, an edge 68 a ofthe lower front lock engagement piece 68 is guided to the incisedportion 51 projecting outward. At this time, the incised portion 51 isresiliently deformed inward, while the lower front lock engagement piece68 is resiliently deformed outward. When the incised portion 51 isthereafter fitted in the engagement hole 69, the incised portion 51 isrestored into its undeformed state, and the lower front lock engagementpiece 68 outwardly projects again. When the upper panel 7 is combinedwith the lower panel 8, the pair of the upper and lower metal panels 7,8 are thus locked to each other with the incised portion 51 projectingoutward in resilient engagement with the engagement hole 69.

With reference to FIGS. 7A to 7F, an explanation will next be given to aprocess for assembling the PC card 1.

An operator first holds the upper panel 7 up side down by one of hishands and obliquely holds the frame 6 against the upper panel 7 by theother hand to bring the pair of pivotal engagement pieces 43, 43provided on the rear edge 7 b of the upper panel 7 in engagement withthe pivotal engagement piece receiving grooves 33, 33 formed in the rearbeams 16, 16 of the frame 6 (see FIGS. 7A and 7B) . Thus, the upperpanel 7 is positioned with respect to the frame 6 along the side edges 7a of the upper panel 7. At the same time, the pivotal engagement pieces43 abut against the positioning abutment portions 33 a, 33 a of thepivotal engagement piece receiving grooves 33, whereby the upper panel 7is positioned with respect to the frame 6 along the rear edge 7 b. Then,the operator rotates the frame 6 about the pivotal engagement piecereceiving grooves 33, 33 as a rotation axis until the front edge of theframe 6 abuts against the upper panel 7 (see FIG. 7C).

In the course of the rotation, the pair of first engagement pieces 55,55 are respectively inserted into the pair of second engagement grooves35, 35, whereby the frame 6 is guided to a proper position on the upperpanel 7. The first engagement pieces 55, 55 respectively have arcuateguide surfaces which are opposed to the frame 6, and the guide surfacesrespectively guide the first engagement pieces 55, 55 into the secondengagement grooves 35, 35 for insertion. Thus, reliable positioning ofthe frame 6 with respect to the upper panel 7 is smoothly achieved atthe initial stage of the rotation of the frame 6, thereby facilitatingthe subsequent operation for combining the frame 6 with the upper panel7.

Then, the frame 6 is further rotated to press-fit the pair of press-fitpieces 53, 53 provided on the opposite side edges 7 a, 7 a of the upperpanel 7 respectively into the pair of first press-fit grooves 30, 30.Further, the upper front lock engagement pieces 50 are respectivelypress-fitted into the through-channels 28. However, the press-fitting ofthe upper front lock engagement pieces 50 into the through-channels 28may precede the press-fitting of the first press-fit pieces 53, 53 intothe first press-fit grooves 30, 30. The upper side lock pieces 44 arelocated alongside the side beams 15 outwardly of the frame 6.

Subsequently, the positioning holes 2 c of the printed board 2 arebrought into engagement with the positioning engagement pieces 23provided in the four corners of the frame 6, whereby the board assembly5 is positioned on the lower face 6 a of the frame 6.

Thereafter, the operator obliquely holds the lower panel 8 against theframe 6, whereby the pair of pivotal engagement pieces 63, 63 providedon the opposite end portions of the rear edge 8 b of the lower panel 8are respectively engaged with the pair of pivotal engagement piecereceiving grooves 33, 33 of the frame 6 combined with the upper panel 7(see FIG. 7D). At this time, the pivotal engagement pieces 63, 63 arerespectively fitted in spaces of the pivotal engagement piece receivinggrooves 33, 33 not occupied by the pivotal engagement pieces 43, 43 ofthe upper panel 7 already engaged therewith (see FIG. 7E)

After the pivotal engagement pieces 63 are brought into abutment againstthe positioning abutment portions 33 a, 33 a of the pivotal engagementpiece receiving grooves 33 thereby to properly position the lower panel8 with respect to the frame 6 along the rear edge 8 b, the operatorrotates the lower panel 8 about the pivotal engagement pieces 63, 63 asa rotation axis until the front edge of the lower panel 8 abuts againstthe frame 6 (see FIG. 7F) At this time, the second engagement pieces 73,73 which respectively have arcuate guide surfaces opposed to the frame 6are operative in the same manner as the first engagement pieces 55, 55of the upper panel 7, so that the lower panel 8 can properly and easilybe positioned with respect to the lower panel 8 and combined therewith.

Then, the operator holds the upper and lower panels 7, 8 by his hands topress the lower panel 8 against the frame 6. Thus, the lower front lockengagement pieces 68 of the lower panel 8 are respectively inserted intothe through-channels 28 which have smaller spaces with the upper frontlock engagement pieces 50 already press-fitted therein, and engaged withthe upper front lock engagement pieces 50. The pair of second press-fitpieces 71, 71 provided on the opposite side edges 8 a, 8 a of the lowerpanel 8 are respectively press-fitted into the corresponding pair ofsecond press-fit grooves 32, 32. Further, the upper and lower side lockpieces 44, 64 are brought into lock engagement with each other. However,the insertion of the lower front lock pieces 68 into thethrough-channels 28, the press-fitting of the second press-fit pieces 71into the second press-fit grooves 32 and the lock engagement of theupper and lower side lock pieces 44, 64, any one of which may precedethe other, may be carried out in any order.

Since the length Wd of the lower front lock engagement pieces 68 isequal to the length of the through-channels 28 as described above, thelower front lock engagement pieces 68 are not press-fitted into theframe 6. As a result, the side lock pieces 44, 64 are snapped intoengagement with each other with a sound when the lower panel 8 ispressed toward the frame 6. The snapping gives a good feeling when thepanels 7, 8 are joined to each other.

With the upper and lower panels 7, 8 combined with the frame 6, thechevron-shaped conductive pieces 54, 54 of the upper panel 7 abutagainst the interior surface of the lower panel 8 opposed thereto,thereby establishing stable electrical conduction between the panels 7and 8.

Thus, the connection between the metal panels 7, 8 and the frame 6 andthe mechanical and electrical connection between the metal panels 7 and8 are achieved.

The first and second engagement pieces 55 and 73 may be adapted to berespectively press-fitted into the corresponding second and firstengagement grooves 35, 34. In this case, the torsion resistance of thePC card 1 can further be improved, so that the PC card 1 can assuredlybe prevented from becoming disassembled.

In accordance with this embodiment, the press-fit pieces 53, 71 arerespectively press-fitted in the press-fit grooves 30, 32 of the frame 6to combine the metal panels 7, 8 with the frame 6 as described above.Therefore, the loose connection between the pair of metal panels 7 and 8can be eliminated. Similarly, the press-fitting of the upper front lockengagement pieces 50 into the through-channels 28 can more assuredlyprevent the loose connection between the metal panels 7 and 8. Thus, thePC card 1 is provided which is imparted with higher impact and torsionresistance and attains a higher level of product perfection.

Since the metal panels 7, 8 are combined with the frame 6 by engagingthe pivotal engagement pieces 43, 63 with the pivotal engagement piecereceiving grooves 33 of the frame 6 and then rotating the metal panels7, 8 relative to the frame, the metal panels 7, 8 can easily bepositioned with respect to the frame 6 along the side edges 7 a, 8 a. Inaddition, the positioning of the metal panels 7, 8 with respect to theframe 6 along the rear edges 7 b, 8 b can easily be achieved, becausethe pivotal engagement pieces 43, 63 abut against the positioningabutment portions 33 a, 33 a of the pivotal engagement piece receivinggrooves 33. Further, the positioning abutment portions 33 a, 33 a areprovided in the opposite ends of the respective pivotal engagement piecereceiving grooves 33, so that the metal panels 7, 8 can assuredly bepositioned with respect to the frame 6 along the rear edges 7 b, 8 b ofthe metal panels 7, 8.

Since the front lock engagement pieces 50 and the side lock pieces 44are brought into lock engagement with the front lock engagement pieces68 and the side lock pieces 64, respectively, the metal panels 7, 8 areprevented from being disengaged from each other.

Further, the side lock pieces 44, 64 are resiliently engaged with eachother, so that the firm connection between the metal panels 7, 8 can beensured after the snap engagement. Since the hook portions 65 arerespectively brought into snap engagement with the engagement holes 49formed in the proximal portions of the guide portions 48, the pair ofmetal panels 7, 8 are connected to each other without any clearance. Asa result, the metal panels 7, 8 thus connected provide a goodappearance. In addition, the second abutment portions 47 and the firstabutment portions 67, which are provided generally entirely along theopposite side edges 7 a, 8 a of the respective metal panels 7, 8, abutagainst each other, so that edge faces of the metal panels 7, 8 arehardly seen from the outside of the finished PC card 1. Thus, the PCcard has a further improved appearance.

Since the frame 6 is a unitary rectangular ring frame, the frame is lessliable to be deformed by an external force. Therefore, a series ofassembling steps including the positioning step for the engagement ofthe pivotal engagement pieces 43, 63 with the pivotal engagement piecereceiving grooves 33 can easily be performed.

FIG. 8 is a perspective view illustrating a pair of front lockengagement pieces according to another embodiment of the PC card 1 ofthe present invention. The pair of front lock engagement pieces 50Aaccording to this embodiment are different from those of the embodimentshown in FIG. 6 in that conductive pieces 81 formed as directingdownward by incising and outwardly raising the upper front lock pieces50A are employed instead of the conductive pieces 54 as the conductionmechanism, and located rearwardly adjacent the incised portions 51 ofthe upper front lock engagement pieces 50A, and the second upstandingportions 62A of the lower front lock engagement pieces 68A extend toreach the conductive pieces 81 when the metal panels 7, 8 are combinedwith each other. In the embodiment shown in FIG. 8, the electricalconnection between the metal panels 7 and 8 can more assuredly beestablished.

While the present invention has been described in detail by way of theembodiments thereof, it should be understood that the foregoingdisclosure is merely illustrative of the technical principles of thepresent invention but not limitative of the same. The spirit and scopeof the present invention are to be limited only by the appended claims.

This application claims priority benefits under the Treaty on the basisof Japanese Patent Application No. 10-103212 filed to the JapanesePatent Office on Apr. 14, 1998, the disclosure thereof beingincorporated herein by reference.

What is claimed is:
 1. A PC card frame kit comprising: a frame forretaining a board assembly having a connector mounted on a board; and apair of panels for covering upper and lower faces of the board assemblymounted in the frame, wherein the pair of panels each have a pivotalengagement piece provided on a rear edge thereof for pivotal engagementwith the frame, front lock engagement pieces provided on front ends ofopposite side edges thereof for lock engagement between the panels, anda press-fit piece provided on at least one of the side edges thereof tobe press-fitted in the frame, wherein the frame has a pivotal engagementpiece receiving groove formed in a rear beam thereof for receiving thepivotal engagement piece in a rotatable manner, and a press-fit grooveformed in at least one of opposite side beams associated with thepress-fit piece for receiving the press-fit piece.
 2. A PC card framekit as set forth in claim 1, wherein the pivotal engagement piecereceiving groove has a positioning abutment portion which is to abutagainst the pivotal engagement piece for positioning the panels withrespect to the frame along the rear edges of the pair of panels.
 3. A PCcard frame kit as set forth in claim 1, wherein the pair of panels eachfurther have a side lock piece provided on at least one of the oppositeside edges thereof for lock engagement between the panels.
 4. A PC cardframe kit as set forth in claim 3, wherein the side lock piecesrespectively provided on the pair of panels are resilient pieces, one ofwhich is formed with a hook portion for preventing disengagement and theother of which is formed with an engagement hole for receiving the hookportion for snap engagement with the hook portion.
 5. A PC card framekit as set forth in claim 3, wherein the side lock piece provided on oneof the pair of panels is a resilient member having an upstanding portionextending upward from the side edge of the panel to fit along the sidebeam of the frame, and a hook portion extending from the upstandingportion in wardly of the frame, wherein the side lock piece provided onthe other panel is a resilient member having a downstanding portionextending downward from the side edge of the panel to fit along the sidebeam of the frame, a guide portion extending obliquely from thedownstanding portion inwardly of the frame for guiding the hook portion,and an engagement hole formed in a proximal portion of the guideportion, wherein the hook portion is guided into the engagement hole bythe guide portion to be brought into snap engagement with the engagementhole by pressing the pair of panels toward each other in an opposedrelation.
 6. A PC card frame kit as set forth in claim 1, wherein one ofthe pair of panels has upstanding portions respectively extending upwardfrom portions of the opposite side edges thereof, and first abutmentportions respectively extending from distal edges of the upstandingportions bent toward the frame, wherein the other panel has downstandingportions respectively extending downward from portions of the oppositeside edges of the panel, and second abutment portions respectivelyextending from distal edges of the downstanding portions bent toward theframe to be opposed to the first abutment portions, wherein the firstabutment portions respectively abut against the second abutment portionswith the pair of panels combined with each other.
 7. A PC card frame kitas set forth in any of claim 1, wherein the frame is a unitaryrectangular ring member having a generally rectangular shape.
 8. A PCcard comprising: a frame kit as recited in any of claims 1; and a boardassembly, wherein the pair of panels are combined with the frame withthe board assembly retained between the pair of panels.
 9. A PC cardframe kit comprising: a rectangularly-shaped frame for retaining a boardassembly having a connector mounted on a board, the frame having a pairof opposing side beams extending parallel to each other; and a pair ofpanels for covering upper and lower faces of the board assembly mountedin the frame and the pair of side beams, wherein the pair of panels eachhave a side lock piece provided on at least one of the opposite sideedges thereof for lock engagement between the panels, wherein the sidelock piece provided on one of the pair of panels is a resilient memberhaving an upstanding portion extending upward from the side edge of thepanel to fit along a side beam of the frame, and a hook portionextending from the upstanding portion toward the side beam, wherein theside lock piece provided on the other panel is a resilient member havinga downstanding portion extending downward from the side edge of thepanel to fit along the side beam of the frame, a guide portion extendingobliquely from the downstanding portion toward the side beam for guidingthe hook portion, and an engagement hole formed in a proximal portion ofthe guide portion, wherein the hook portion is guided into theengagement hole by the guide portion to be brought into snap engagementwith the engagement hole by pressing the pair of panels toward eachother in an opposed relation.
 10. A PC card frame kit as set forth inclaim 7, wherein the upstanding portion extends substantially along eachof the opposite side edges of the one panel, wherein the downstandingportion extends substantially along each of the opposite side edges ofthe other panel, wherein the one panel further includes a first abutmentportion extending from a distal edge of the upstanding portion towardthe frame to connect the upstanding portion with the hook portion,wherein the other panel further includes a second abutment portionextending from a distal edge of the downstanding portion toward theframe to connect the downstanding portion with the guide portion.
 11. APC card production method, in which a first panel and a second panel areattached to a frame retaining a board assembly having a connectormounted on a board to cover upper and lower faces of the board assemblymounted in the frame, the PC card production method comprising the stepsof: bringing a pivotal engagement piece provided on a rear edge of thefirst panel into engagement with a pivotal engagement piece receivinggroove formed in a rear beam of the frame; rotating the first panel withrespect to the frame about the pivotal engagement piece thereof as arotation axis until a front edge of the first panel abuts against theframe; bringing a pivotal engagement piece provided on a rear edge ofthe second panel into engagement with the pivotal engagement piecereceiving groove formed in the rear beam of the frame; rotating thesecond panel with respect to the frame about the pivotal engagementpiece thereof as a rotation axis until a front edge of the second panelabuts against the frame; and pressing the first and second panelsagainst the frame to combine the first and second panels with each otherand with the frame.
 12. A PC card production method as set forth inclaim 11, wherein the combining step comprises the steps of: engagingfront lock engagement pieces provided on front end portions of oppositeside edges of the first panel with front lock engagement pieces providedon front end portions of opposite side edges of the second panel; andpress-fitting a press-fit piece provided on at least one of the sideedges of each of the first and second panels into a press-fit groove ofthe frame.